Shielded strap system

ABSTRACT

A shielded strap system for binding loose materials while resisting damage to the materials. The strap system includes a high tensile strength elongated core having an outer protective sleeve. The core can comprise a flat metal strap capable of being stretched to tightly bind the loose materials into a stable bundle. The outer protective sleeve can comprise a coating which partially or completely covers the core. The outer protective sleeve can be shaped to provide extra protection at the core edges for protecting the loose materials against breakage or abrasive wear.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to-systems for retaining a single material and for binding individual materials into a bundle. More particularly, the invention relates to a shielded strap system for binding materials and for protecting the materials against abrasion and other strap induced damage.

[0002] Flat bands or straps bind many different types of materials. Such straps typically comprise an elongated binder which can be wrapped around the loose materials and cinched to contain the materials. Although fibrous and plastic strap binders are used in certain applications, the tensile strength of such straps is often less than the tensile strength of steel straps. Flat metal straps provide significant tensile strength and resist separation and other damage. Although metal wire can bind materials, flat metal bands increase the surface area of the binder in contact with the contained materials. By increasing band surface area contact against the bound materials, puncture damage and deformation of the materials is minimized.

[0003] Representative materials contained by metal straps include spooled cable, bricks and other masonry products, flexible sacks containing powdered or pelleted material, lumber, tubular products, and many other product types. When the strap contacts a flat planar surface of a material or material bundle, little or no damage occurs between the strap and the material. However, a significant amount of product damage can occur when the strap bends around a corner of the material or material bundle. As the metal strap is cinched down to provide a tight containment around the material bundle, the metal strap typically draws the individual materials together and damages the material bundle corner.

[0004] Bundle corner damage is a significant cost in product storage and transportation or deformable and nondeformable products. For deformable loose materials such as lumber, the tightened metal strap compresses the lumber on the corner and permanently deforms the corner edge. For deformable loose materials such as spooled cable having an outer plastic sheath, the metal strap compresses the outer sheath surface and can physically cut the outer plastic sheath surface. If the plastic sheath provides a weathering surface for the cable product, the cut must be repaired before the cable can used. For deformable materials such as a bundle of flexible sacks, the metal strap can cut the sack and release the sack contained material.

[0005] The forces exerted by metal straps on bundled loose materials can also damage relatively nondeformable materials. Cementitious products such as fired bricks are brittle and are susceptible to notch sensitivity failures. If a tightened strap binds the corner of a brick stack, the concentration of strap force at the corner can break the brick in contact with the strap. In addition to damaging the corner brick, such breakage can loosen the strap around the entire bundle if the broken brick pieces are displaced from the original bound position. Once the strap is loosened, failure of the entire bundle can occur during transport.

[0006] In addition to the failures described above, flat metal straps have relatively sharp edges capable of abrading or cutting loose materials in contact with the strap. Painted tubular products such as pipe tubulars are frequently painted with anti-corrosion paints which can become scarred or scratched by contact with metal strap edges. Such damage may require labor intensive repair if the tubulars will be used in long service or high corrosion environments. Additionally, thin walled tubulars such as PVC pipe can be deformed or unnecessarily stressed by the tie-down force applied as the metal bands are cinched down to contain the tubulars.

[0007] Prior art techniques for minimizing metal strap damage typically use localized patches. Such techniques position spacers, cushion pads or “chairs” at strategic locations between the metal strap and the bound materials. Cardboard or plastic spacers are hand positioned between the metal strap and the materials before the metal strap is tightened to cinch the materials. This process requires hand labor and can be ineffective if the cinched metal strap dislocates the spacer during the binding process. Upon such event, extra labor is required to hold the spacer in position as the metal strap is cinched, and the risk of hand injury is increased.

[0008] In addition to these limitations, plastic spacers or chairs are separate from the metal strap and require handling and storage. Because such spacers are often constructed for a particular task, an appropriate spacer may not be available for a particular application. For example, plastic corner protectors used for protecting the corners of loaded brick pallets are not suitable for protecting tubular product bundles or bundles formed with flexible sacks. Similarly, paper spacers used between metal straps and tubular products are not suitable for binding bundles formed with cardboard boxes. The need for various spacers increases the required variety of spacer inventory, slows operations, and encourages the improper use of spacers unsuited for the application.

[0009] A need exists for an improved strap system capable of providing high tensile tie-down forces without damaging the bound materials. The system should be economic to manufacture, should be adaptable to multiple applications, and should resist damage to the bound material.

SUMMARY OF THE INVENTION

[0010] The invention provides a shielded strap system for binding a material or a combination of materials. The invention comprises an elongated core resistant to tensile separation and sufficiently flexible to be engagable with the material, a core end capable of being attached to another portion of said core, and a sleeve engaged with said core and positioned between said core and the material.

[0011] In different embodiments of the invention, the core can comprise a metal band or can comprise different configurations or materials. The sleeve can partially or substantially cover the core and can comprise a plurality of discontinuous dimples, a linear ridge, or other shape. The sleeve can have a thicker cross-section near opposing edges of the band and can be partially removable from the core to permit engagement of the core with the material. The sleeve can perform multiple functions such as resisting damage to the material or to the core, and of resisting movement relative movement between the core and the material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 illustrates the invention engaged with a single material.

[0013]FIG. 2 illustrates a cross-sectional view for inventive embodiment.

[0014]FIG. 3 illustrates a band engaged with a material bundle.

[0015]FIG. 4 illustrates multiple bands binding a bundle of flexible sacks.

[0016]FIG. 5 illustrates a sheath formed with discontinuous dimples.

[0017]FIG. 6 illustrates a sheath formed with separate end caps protecting each opposing edge of the band.

[0018]FIG. 7 illustrates a sheath having a uniform thickness.

[0019]FIG. 8 illustrates a sheath formed on one surface of a band.

[0020]FIG. 9 illustrates a sheath is engaged with a portion of the band.

[0021]FIG. 10 illustrates an embodiment of the invention wherein a sheath initially covers the band and is partially pulled back to expose a free band end.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] The invention relates to a shielded strap system for binding a materials. The invention can be engaged with a single material or can bind multiple materials into a single bundle. The invention is applicable to a wide variety of materials and can bind a material or material bundle while resisting potential damage to the material.

[0023]FIG. 1 illustrates one embodiment of the invention wherein an elongated core such as band 10 is engaged with a material identified as box 12. As shown in FIG. 2, band 10 has two generally parallel, flat surfaces identified as first surface 14 and second surface 16. First surface 14 is proximate to box 12, and second surface 16 faces away from box 12. Edges 18 complete outer surface shaping band 10. Band 10 is formed with a flexible material resistant to tensile separation and provides a structural member for binding box 12.

[0024] Sheath 20 is illustrated as being engaged with band 10. Sheath 20 can comprise an organic or inorganic material and can comprise numerous forms. In a preferred embodiment of the invention as shown in FIG. 2, sheath 20 can comprise a plastic or elastomeric material bound or otherwise attached to or engaged with band 10. Sheath 20 can be heat shrunk to enclose all or a portion of band 10, and can have a uniform thickness. Alternatively, sheath 20 can have a shape wherein the thickness of sheath 20 is variable about band 10. As shown in FIG. 2, sheath 20 can have protrusions 22 which extend outwardly from sheath body 24. Protrusions 22 can be made of a selected material thickness sufficient to contact box 12 and to provide a contact surface against box 12 resistant to movement therebetween. Band end 26 is attachable to another portion of band 10 identified as band section 28.

[0025] Sheath body 24 and protrusions 22 can be formed with different materials and configurations to accomplish different objectives. One function provided by sheath 20 is to prevent moisture and other compounds from contacting and degrading band 10. Another function of sheath 20 is to provide surface contact against box 12 which is resistant to slippage or other relative movement. Sheath 20 can have a composition providing a relatively high degree of friction relative to material 12. Alternatively, sheath 20 can have an adhesive or binding quality relative to material 12 which can be provided by the structure or composition of sheath 20. Structurally, a softer or “sponge-like” composition of sheath 20 can provide greater gripping capability than a hard, unyielding composition. Sheath 20 can have ridges, serrations, ridges, and other surface discontinuities tending to facilitate contact between sheath 20 and material 12. In other embodiments of the invention, sheath 20 can be discontinuous over the exterior surface of band 10 to provide a selected pattern or footprint for gripping material 12.

[0026] A significant function provided by sheath 20 is to resist damage to material 12 as band 10 is cinched tightly into contact with material 12. When conventional metal bands are cinched tightly around a material or bundle of materials, the metal band and sharp metal edges compress and cut into the bound material. Sheath 20 resists such damage in several ways. First, sheath 20 provides a gripping function against material 12 which lessens the force required to bind material 12. Consequently, the reduced binding force reduces the compression and localized pressure exerted against material 12. Secondly, sheath 20 can provide a softer surface against material 12 which automatically adjusts to surface variations in the exterior of material 12, or in the outer surface of material bundle 30 between individual material bundle components. Additionally, sheath 20 can slide relative to band 10 so that sheath 20 can remain fixed against material 12 as band 10 is moved relative to sheath 20 to tension band 10 against material 12 or material bundle 30.

[0027]FIG. 3 illustrates the application of the invention to a plurality of materials collectively identified as material bundle 30. Material bundle 30 can comprise a variety of individual materials including product filled sacks, bricks and other masonry products, lumber and other wood products, boxes, plastic pipe, As shown in FIG. 3, band 10 and sheath 20 have been positioned about an exterior surface of material bundle 30 and have been cinched tightly against material bundle 30 to bind the individual materials. Connection 32 provides the attachment mechanism for engaging band 10 and sheath 20 with material bundle 30. Connection 32 can be made with different mechanical or adhesive techniques. If band 10 comprises a structure similar to conventional metal straps, connection 32 can be formed with conventional crimping techniques. In other embodiments of the invention, connection can be mechanically formed with a clasp or other mechanical connector.

[0028] Because band 10 comprises metal in a preferred embodiment of the invention, sheath 20 extends the useful life of band 10 by protecting band 10 from corrosion and notch failures. Consequently, the connection between band free end 26 and the engagement point of band 10 can be accomplished with mechanical connectors of different designs and constructions. Such mechanical connectors can be discarded after one use or can be reusable to permit subsequent use of band 10 and sheath 20 to another material 12 having a similar shape or form. In this manner, the invention reduces material waste by providing a reusable product having extended use.

[0029]FIG. 4 illustrates an embodiment of the invention wherein material bundle 34 is formed with a plurality of loosely filled sacks which are deformable when compressed. A single band 10 and sheath 20 can be engaged with material bundle 34, or multiple bands 10 and associated sheaths 20 can be engaged with material bundle as illustrated.

[0030]FIG. 5 illustrates another embodiment of the invention wherein band 10 is engaged with sheath 36 formed with discontinuous dimples 38. Dimples 38 can be glued, painted, sprayed or otherwise affixed to or associated with band 10. FIG. 6 illustrates another embodiment of the invention wherein sheath 40 comprises two end caps engaged with each opposing edge of band 10. In this embodiment of the invention, the material used for sheath 40 is minimized and the protection provided by sheath 40 against edge abrasion and cutting by the edges of band 10 is maximized. FIG. 7 illustrates another embodiment of the invention wherein sheath 42 has a uniform thickness around the exterior surface of band 10. FIG. 8 illustrates an embodiment of the invention wherein sheath 44 is positioned on first side 14 of band 10, and FIG. 9 illustrates an inventive embodiment wherein a section of body 10 is engaged with sheath 46.

[0031] To use the invention, band 10 can have first end 26 uncovered by sheath 20. If sheath 20 initially covers first end 26, sheath 20 can be cut back or otherwise partially removed to expose first end 26 as illustrated in FIG. 10. Subsequently, first end 26 is attached to a middle portion of band 10 identified as band section 28. If band section 28 is initially covered with sheath 20, a portion of sheath 20 can be removed to expose band section 28 and to permit direct contact between band first end 26 and band section 28. After such contact is made, band first end 26 can be attached to band section 28 with conventional attachment techniques known in the art. If desired, a protective coating can be painted, sprayed, or otherwise formed on or attached to the connection between band first end 26 and band section 28 to prevent corrosion or to protect material 12 from abrasive contact with such connection.

[0032] The invention uniquely protects a material from damage as the material is bound for storage or transport. The invention is cost effective to produce, is applicable to multiple and varied applications, and reduces labor cost. The invention can be stored on a spool or reel in a manner similar to the storage techniques for conventional metal straps, and can be dispensed by rotating the storage spool. The invention conserves material and resources by providing a product which can be reused to bind another material, or which can be recycled into the raw components for remanufacture. The durability of the invention supports design and application of reusable clasps which can selectively bind and release band 10 and sheath 20 into engagement with a material bundle.

[0033] Although the invention has been described in terms of certain preferred embodiments, it will be apparent to those of ordinary skill in the art that modifications and improvements can be made to the inventive concepts herein without departing from the scope of the invention. The embodiments shown herein are merely illustrative of the inventive concepts and should not be interpreted as limiting the scope of the invention. 

What is claimed is:
 1. An apparatus for binding a material, comprising: an elongated core resistant to tensile separation, wherein said core is sufficiently flexible to be placed into engagement with the material, and wherein said core has an end capable of being attached to another portion of said core to bind the material; and a sleeve engaged with said core and positioned between said core and the material.
 2. An apparatus as recited in claim 1, wherein said core is positionable into engagement with at least two materials to bind the materials.
 3. An apparatus as recited in claim 1, wherein said sleeve comprises a plurality of discontinuous dimples between said core and the material.
 4. An apparatus as recited in claim 1, wherein said sleeve comprises a linear ridge substantially parallel to said elongated core.
 5. An apparatus as recited in claim 1, wherein said sleeve substantially covers said core.
 6. An apparatus as recited in claim 5, wherein said sleeve has a surface in contact with the material, and wherein said surface is shaped so that only a portion of said sleeve surface contacts the material.
 7. An apparatus as recited in claim 1, wherein said core comprises a metallic strap having two substantially flat surfaces and two opposing edges.
 8. An apparatus as recited in claim 7, wherein said sleeve is engaged with said opposing edges of said core.
 9. An apparatus as recited in claim 7, wherein said sleeve is engaged with said opposing edges of said core and with at least one substantially flat surface, and wherein said sleeve portion engaged with said core opposing edges as a cross-section thicker than the sleeve portion engaged with said core flat surface.
 10. An apparatus as recited in claim 1, wherein said sleeve resists movement between said core and the material when said core is engaged with the material.
 11. An apparatus as recited in claim 1, wherein said sleeve substantially covers said core, and wherein said sleeve is partially removable from engagement with said core to permit attachment of said core end to the other portion of said core.
 12. An apparatus for binding materials together, comprising: a band resistant to tensile separation, wherein said band is sufficiently flexible to be placed around the materials, and wherein said band has an end capable of being attached to another portion of said band to bind the materials together; and a protective sleeve engaged with said band and positioned between said band and the materials.
 13. An apparatus as recited in claim 12, wherein said sleeve is capable of resisting damage to the materials caused by said band.
 14. An apparatus as recited in claim 12, wherein said sleeve is capable of protecting said band by resisting corrosion of said band.
 15. An apparatus as recited in claim 12, wherein said band comprises a metal material and said sleeve comprises a plastic material.
 16. An apparatus as recited in claim 12, wherein said sleeve is attached to said band.
 17. An apparatus as recited in claim 12, wherein said sleeve is moveable relative to said band when said band end is attached to the other portion of said band.
 18. An apparatus as recited in claim 12, further comprising an adhesive material attached to said sleeve for contacting the materials and for resisting movement between said sleeve and the materials. 